Disposable Overshoe

ABSTRACT

A disposable overshoe preferably made from a single-ply sheet of waterproof material folded on top of itself to form a double ply-sheet with a fold at the bottom. The toe of the disposable overshoe can be made by fusing the double-ply sheet to itself to form a toe-side connection running from the fold at the bottom to an opening between the double-ply sheets at a top. Likewise, the heel of the disposable overshoe can be made by fusing the double-ply sheet to itself to form a heel-side connection running from the fold at the bottom to the opening at the top. By orienting and forming the toe-side and heel-side connections to the size and shape of a shoe, an opening at the top can be left to allow a shoe to fit between the opening in the double-ply sheet. In this way, a user can insert the toe of the user&#39;s shoe into the opening, and cinch a strap around the user&#39;s leg to protect the inside of the disposable overshoe from the outside elements.

FIELD OF THE INVENTION

The present inventions relates to overshoes, and in particular to disposable, waterproof overshoes.

SUMMARY

The present disclosure includes improvements to waterproof overshoes. Broadly, the invention is embodied by a disposable overshoe preferably made from a single-ply sheet of waterproof material. The single ply sheet is folded on top of itself to form a double ply-sheet with a fold at the bottom. The toe of the disposable overshoe can be made by fusing the double-ply sheet to itself to form a “toe-side connection”, the toe-side connection running from the fold at the bottom to an opening between the double-ply sheets at a top. The toe-side connection is preferably curved to accommodate the shape of the toe end of a shoe. Likewise, the heel of the disposable overshoe can be made by fusing the double-ply sheet to itself to form a “heel-side connection”, the heel-side connection running from the fold at the bottom to the opening at the top. The distance between the toe-side connection and the heel-side connection varies depending on the desired shoe size. Likewise the contours of the toe-side connection and heel side connection vary depending on the shape of the shoe to be protected.

A cuff of the double-ply sheet is preferably left above the opening. The purpose of the cuff is to both provide a location for a strap and so that the cuff can be folded over the strap after the strap is cinched to a user's lower leg.

The strap, which is preferably unitary with the double-ply sheet, extends out from the cuff. If there is no cuff, the strap can extend from the heel-side connection. The strap is preferably fused (heat-sealed) at its end. This allows the strap to be extended in length if the user tears off a single ply near the heel-side connection.

By orienting and forming the toe-side and heel-side connections to the size and shape of a shoe, an opening at the top can be left to allow a shoe to fit between the opening in the double-ply sheet. In this way, a user can insert the toe of the user's shoe into the opening between the double-ply sheet and orient the shoe between the toe-side connection and the heel-side connection. After inserting the shoe, the user can cinch the strap around the user's leg to protect the inside of the disposable overshoe from the elements.

Numerous other advantages and features of the present invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims and from the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS OR PICTURES

The objects, features and advantages of the present invention will be more readily appreciated upon reference to the following disclosure when considered in conjunction with the accompanying drawings, wherein reference numerals are used to identify the components in the various views.

FIG. 1 illustrates a single-ply layer of polyester polyurethane film die-cut into a shape suitable for this invention.

FIG. 2 illustrates a first fold-line A-A and a second fold line B-B for creating a pleated sole.

FIG. 3 illustrates an alternate embodiment having a separate cuff piece.

FIG. 4 illustrates dimensions of an embodiment of a single-ply layer of polyester polyurethane film die-cut into a shape suitable for this invention.

FIG. 5 illustrates the preferred embodiment of this invention.

FIG. 6 illustrates an alternative embodiment this invention.

FIG. 7 illustrates end view C-C from FIG. 5.

FIG. 7A illustrates Detail A from FIG. 7.

FIG. 8 is a photo of a user wearing an embodiment of the invention.

FIG. 8A is a photo of a user wearing an embodiment of the invention.

DESCRIPTION OF THE EMBODIMENTS

The invention or features thereof described herein are adaptable to embodiments having many different forms and functions related to the disclosure herein. The embodiment shown in the drawings and is described below is an example of the principles of the invention and is not intended to limit the invention to the specific embodiment(s) illustrated. Embodiments consistent with the present invention may be alternately embodied, practiced, and/or carried out in various ways or implementations. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract included below, are for the purposes of description and should not be regarded as limiting. Reference throughout this specification to “embodiment” should inform a person having ordinary skill that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention but not necessarily in all embodiments. The features, structures, or characteristics of any embodiment of the present invention may be combined in any suitable manner and in any suitable combination with one or more other embodiments, including the use of selected features without corresponding use of other features. Modifications may be made to adapt an implementation of certain features to the essential scope and spirit of the present invention and certain features, limitations, or elements of each embodiment can be omitted or replaced with equivalents. Other variations and modifications of the embodiments of the present invention are possible and are part of the spirit and scope of the present invention. Finally, the disjunctive term “or” herein, is generally intended to mean “and/or”, having both conjunctive and disjunctive meanings (i.e. not an “exclusive or” meaning), unless so indicated. And, as used in the description herein and throughout the claims that follow, “a”, “an”, and “the” should be interpreted as “at least one” and include plural references unless the context dictates otherwise.

The invention is incorporated in a disposable overshoe and a method for making such overshoes. The preferred disposable overshoe is made from polyester polyurethane film. Polyester polyurethane film is flexible, waterproof, slip-resistant, and puncture-resistant. Other materials possessing these characteristics may be known in the art and suitable for this invention.

In general, a disposable overshoe can be created by heat-sealing (i.e., heat-staking or welding) a partial-perimeter 24 of two, single-ply sheets 10 of polyester polyurethane film. Heat sealing is known by those in the art. In this case, the preferred method of heat sealing applies a high frequency (heating) current through two or more layers of thermoplastic material placed between two sealing electrodes (or dies). Typically, one die is shaped in the image of the desired contour. The other die may have the same shape or may be a flat plate. The dies are usually mounted on a pneumatic or hydraulic press to provide pressure for fusing the materials. The high frequency energy melts the plastic between the dies and fuses the two layers together, joining them.

In addition, it is preferred to cut the excess material from the sealed edge. This can be accomplished by a “seal & cut” process. Special tooling and presses are used to cut away the excess material from the sealed edge. While it is possible just to tear the excess material away from the heat sealed edge, that method is not preferred because it can lead to holes and rips in the plastic, which is not suitable for the end product.

As shown in FIG. 5, folding along lines A-A and B-B, and heat-sealing a partial-perimeter 24 leaves an opening 30 for a shoe to be inserted between the two sheets 10. When a shoe is inserted into the opening 30, the shoe is then protected from the elements on the sides and bottom, but open on the top.

It is also preferred to include a fastening strap 12. The purpose of the fastening strap 12 is to cinch the top of the overshoe against the user's lower leg, thereby sealing the opening off from the outside elements. The fastening can be done by any way known in the art, such as hook and loop, but a foam-style double sided adhesive tape is preferred for a single use embodiment. One suitable adhesive is a double coated foam tape made by 3M #4462. When using double sided tape, one side can be fixed to the strap prior to use so that the user can just peel off the other side and secure the strap to the top of the overshoe. Once the fastening strap 12 is secured around the user's leg, an optional cuff 18 can be folded down over the fastening strap 12. When working in concert, the fastening strap 12, the fold lines (A-A, B-B), and heat-sealed perimeter 24 keep the elements (e.g., dirt, rain, and snow) off of the wearer's shoes.

Various overshoe embodiments are shown in FIGS. 1-6. The preferred embodiment is shown in FIG. 5. A preferred embodiment of the disposable overshoe comprises two side sheets 10, at least one fastening strap 12, and a pleated bottom portion 22.

The bottom portion 22 of the preferred embodiment has a first side, a second side, a front end 14, and a back end 16. In the preferred embodiment, the bottom portion 24 is folded along fold lines “A-A” and “B-B” running from the front end 14 to the back end 16 into four equal, elongated panels, with the middle panels folded inward. Section view C-C, shown in FIG. 7A, illustrates how the bottom portion is preferred to be folded. The four panels of the bottom portion 22 in this embodiment are heat-sealed (heat-staked, welded) together at the front end 14 and back end 16 respectively. In this way, the bottom portion 22 of the preferred embodiment is folded in the default configuration and its front and back ends are curved.

The preferred embodiment of the overshoe has two configurations—a collapsed (i.e., default or folded) configuration for storage and an open or unfolded configuration for use. When the preferred embodiment is in its collapsed configuration, the center of bottom portion 22 is folded inward, along axis A-A extending from the front side 16 to the back side 18 of the embodiment (i.e. from the toe to the heel), and the whole embodiment becomes flat and can be easily stored.

When the preferred embodiment is in its open configuration, the side sheets 10 and the bottom portion 22 are configured to receive a shoe up to the ankle portion of the shoe wearer while the fastening strap 12 is configured to encircle the top section 18 of the side sheets 10 and secure the embodiment at or near the shoe wearer's ankle. Additionally, when the shoe wearer wears the preferred embodiment with the fastening strap 12 secured, the top section 18 of the side sheets 10 may be folded down to form a cuff and hide the fastening strap 12, which may make the embodiment more aesthetically appealing.

To form the preferred embodiment of FIG. 5, pleats are formed in a single-ply sheet to create bottom portion 22 and the pleated folds at A-A and B-B. These pleated folds ultimately create the “w” (or “double fold”) shape shown in FIG. 7A. The front side 14 and back side 16 are then heat sealed in the desired shape, preferably as shown in FIG. 5. The waste is then stripped away, either by hand or mechanically.

Fastening strap 12 is then welded along interface 28. Fastening strap 12 can be made from a single-ply sheet cut in the shape shown in FIG. 5. In this embodiment, fastening strap 12 is cut long enough to allow a user to wrap fastening strap 12 around a user's ankle to seal the top with adhesive pad 32.

Alternatively, fastening strap 12 can be made from a double-ply sheet and heat-sealed (or welded or folded) on edge 26. This allows the double-ply strap 12 to shorter than if it was made a single-ply strap 12. For example, one of the single-ply side sheets 10 can be ripped or cut near interface 28 to form extension section 30. FIG. 5 illustrates a strap 12 that has been ripped near interface 28. Ripping a single-ply of strap 12 near interface 28 effectively doubles the length of the fastening strap 12 because edge 26 becomes the middle of an elongated single-ply strap (the combined sections 12 and 30 shown in FIG. 5). Adhesive pad 32 can then be affixed to extension section 30 as shown in FIG. 5. Alternatively, the adhesive pad can be affixed prior to cutting one of the side sheets 10 near interface 28.

In the preferred embodiment, the side sheets 10, at least one fastening strap 12, and the bottom portion 22 are made in one piece, and partially integrally coupled to each other. The preferred embodiment is made of flexible materials that can be welded and joined by heat, such as polyurethane.

In another embodiment, the side sheets 10 can couple to each other at the front and back sides, attach to the at least one fastening strap 12 at the top, back side of one of the side sheets 10, and affix to the bottom side at their bottom sides.

In general, the preferred steps to make a disposable overshoe according to this invention comprise the following:

-   -   (a) Folding a single-ply sheet 10 of waterproof material on top         of itself (FIG. 5).     -   (b) Heat-sealing a toe-side connection 14 by fusing the         double-ply sheet to itself, the toe-side connection running from         the fold at the bottom (B-B) to an opening at a top.     -   (c) Heat-sealing a heel-side connection 16 by fusing the         double-ply sheet to itself, the heel-side connection 16 running         from the fold at the bottom (B-B) to the opening at the top.     -   (d) Cutting off the excess waterproof material to leave a         boot-shape double-ply material with a fold at the bottom, an         opening 30 at the top to allow a shoe to fit between the opening         30 in the double-ply sheet, and a cuff 18 above the opening 30,         the cuff comprising a strap 12.     -   (e) Heat-sealing an end 26 of the strap 12 to that both layers         of the double-ply sheet are fused to itself.

Alternatively, the folding step can be a double fold as shown in FIGS. 7 and 7A. Also, an one can add an adhesive pad (or “strip”) 31 to a face of the strap near the heel-side connection (or “interface”) 28.

While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents and all such modifications that fall within the scope of the claims. 

1. A disposable overshoe, the disposable overshoe comprising, a single-ply sheet of waterproof material, the single ply sheet comprising a fold at a bottom so that the flexible sheet is folded on top of itself to form a double ply-sheet with a fold at the bottom, a toe-side connection fusing the double-ply sheet to itself, the toe-side connection running from the fold at the bottom to an opening between the double-ply sheets at a top, a heel-side connection fusing the double-ply sheet to itself, the heel-side connection running from the fold at the bottom to the opening at the top, a cuff of the double-ply sheet located above the opening, and a strap of the double-ply sheet emanating from the cuff, the strap comprising an end, wherein the end is fused to itself so that a user can break one ply of the strap near the heel side connection to increase the length of the strap, wherein the opening is configured to allow a shoe to fit between the opening in the double-ply sheet at the top so that a toe of the shoe can be oriented near the toe-side connection and a heel of the shoe oriented near the heel-side connection, and wherein the strap can cinch the opening against a user's lower leg after the user has inserted a shoe into the opening.
 2. The disposable overshoe of claim 1, the fold comprising a double-fold.
 3. The disposable overshoe of claim 1, the strap comprising an adhesive strip.
 4. A method of making a disposable overshoe, the method comprising the steps of: folding a single-ply sheet of waterproof material on top of itself, heat-sealing a toe-side connection by fusing the double-ply sheet to itself, the toe-side connection running from the fold at the bottom to an opening at a top, heat-sealing a heel-side connection by fusing the double-ply sheet to itself, the heel-side connection running from the fold at the bottom to an opening at the top, cutting off the excess waterproof material to leave a boot-shaped double-ply material with a fold at the bottom, an opening at the top to allow a shoe to fit between the opening in the double-ply sheet, and a cuff above the opening, the cuff comprising a strap, and heat-sealing an end of the strap so that both layers of the double-ply sheet are fused to itself.
 5. The method of claim 4, wherein the folding step comprises a double fold.
 6. The method of claim 4, further comprising the step of adding an adhesive strip to a face of the strap near the heel-side connection. 